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Freelander 1. Manual - part 12

GENERAL DATA

04-9

Engine – KV6 Petrol

General

Type

2.5 litre V6 direct injection petrol, 24 valve, air assisted fuel injection,
water cooled, transverse mounted

Cylinder arrangement:

V6, numbered from the front of the engine

⇒

Left bank

Cylinders 1, 3 and 5

⇒

Right bank

Cylinders 2, 4 and 6

Bore (nominal)

80 mm (3.15 in.)

Stroke

82.8 mm (3.26 in.)

Capacity

2497 cm

(152.37 in

)

Firing order

1-6-5-4-3-2

Compression ratio

10.5 : 1

0.5 : 1

Direction of rotation

Clockwise viewed from front of engine

Maximum power

130 kW (177 bhp) @ 6500 rev/min.

Maximum torque

240.0 Nm (177 lbf.ft) @ 4000 rev/min.

Maximum engine speed:

⇒

Continuous

6500 rev/min.

⇒

Intermittent

6750 rev/min.

Idle speed

750 rev/min.

50 rev/min.

Weight (fully dressed, wet)

154 kg (340 lb)

Dimensions (dressed):

⇒

Length (nominal)

770 mm (30.3 in.)

⇒

Width (nominal)

750 mm (29.5 in.)

⇒

Height (nominal)

750 mm (29.5 in.)

Valve operation

Self-adjusting lightweight hydraulic tappets operated directly by the
camshafts

Fuel injection system:

⇒

Make

Siemens engine management system

⇒

Type

Multi-point, air assisted fuel injection controlled by ECM and electro-
mechanical injectors with twin sprays targeted at back of inlet valves

Inlet manifold

Variable geometry

Spark plugs

⇒

Make / Type

⇒

Plug gap

GSP 66527
1.0 mm

0.05 mm (0.039 in.

0.002 in.)

Coils:

⇒

Make

⇒

Type

BREMR
6 x coils (3 x plug top, 3 x remote mounted)

Emissions standard

ECD3

Cylinder head

Type

Aluminium alloy

Cylinder head gasket *

Multi-layer steel

Cylinder head warp:

⇒

Lateral

⇒

Longitudinal

0.025 mm (0.001 in)
0.2 mm (0.08 in)

Cylinder head height
Reface height - minimum

118.95 - 119.05 mm (4.683 - 4.687 in)
118.95 mm (4.683 in)

Cylinder block

Type

Cosworth cast aluminium alloy with bearing ladder bolted to bottom of
block

Cylinder liner type

Damp, bottom half stepped - sliding fit into lower part of cylinder block

GENERAL DATA

04-10

Cylinder liner bore:

⇒

RED grade A

80.000 - 80.015 mm (3.1496 - 3.1502 in.)

⇒

BLUE grade B

80.015 - 80.030 mm (3.1502 - 3.1508 in.)

Crankshaft

Material / Type

Cast spheroidal graphite iron with cold rolled fillets on all journals
except outer mains

Crankshaft end-float

⇒

Service limit

0.10 - 0.30 mm (0.004 - 0.012 in.)
0.40 mm (0.016 in.)

Main journal diameter:

⇒

Grade 1

67.743 - 67.749 mm (2.6670 - 2.6673 in.)

⇒⇒

Grade A (Green)

†

⇒⇒

Grade B (Yellow)

†

⇒⇒

Grade C (Black)

†

⇒

Grade 2

67.737 - 67.743 mm (2.6668 - 2.6670 in.)

⇒⇒

Grade A (Blue)

†

⇒⇒

Grade B (Green)

†

⇒⇒

Grade C (Yellow)

†

⇒

Grade 3

67.731 - 67.737 mm (2.6666 - 2.6668 in.)

⇒⇒

Grade A (Red)

†

⇒⇒

Grade B (Blue)

†

⇒⇒

Grade C (Green)

†

Maximum out of round

0.010 mm (0.0004 in.)

Main housing diameter:

⇒

Grade A

71.600 - 71.593 mm (2.8189 - 2.8186 in.)

⇒

Grade B

71.593 - 71.586 mm (2.8186 - 2.8183 in.)

⇒

Grade C

71.586 - 71.579 mm (2.8183 - 2.8181 in.)

Big-end journal diameter:

⇒

Grade A

54.049 - 54.055 mm (2.1279 - 2.1281 in.)

⇒

Grade B

54.043 - 54.049 mm (2.1277 - 2.1279 in.)

⇒

Grade C

54.037 - 54.043 mm (2.1274 - 2.1277 in.)

⇒

Maximum out of round

0.010 mm (0.0004 in.)

Big-end housing diameter:

⇒

Grade 7

57.677 - 57.671 mm (2.2707 - 2.2705 in.)

⇒⇒

Grade A (Green)

⇒⇒

Grade B (Blue)

⇒⇒

Grade C (Red)

⇒

Grade 8

57.671 - 57.665 mm (2.2705 - 2.2703 in.)

⇒⇒

Grade A (Yellow)

⇒⇒

Grade B (Green)

⇒⇒

Grade C (Blue)

⇒

Grade 9

57.665 - 57.659 mm (2.2703 - 2.2700 in.)

⇒⇒

Grade A (Black)

⇒⇒

Grade B (Yellow)

⇒⇒

Grade C (Green)

†

Cylinder block / bearing ladder bore diameter grades

Crankshaft big-end journal grades

Main bearings

Quantity

Material / type

Glacier AS15 - oil grooves in upper half shells, plain lower half shells

Clearance in bearings

0.021 - 0.039 mm (0.0008 - 0.0015 in.)

Thrust washers:

General

GENERAL DATA

04-11

⇒

Type / position

Glacier AS15 - thrust washer halves at top and bottom of rear main
bearing, oil grooves in top and bottom halves

⇒

Thrust washer halves thickness

2.61 - 2.65 mm (0.103 - 0.104 in.)

Main bearing thickness:

⇒

Red

1.930 - 1.927 mm (0.0760 - 0.0759 in.)

⇒

Blue

1.927 - 1.924 mm (0.0759 - 0.0757 in.)

⇒

Green

1.924 - 1.921 mm (0.0757 - 0.0756 in.)

⇒

Yellow

1.921 - 1.918 mm (0.0756 - 0.0755 in.)

⇒

Black

1.918 - 1.915 mm (0.0755 - 0.0754 in.)

Big-end bearings

Material / Type

Glacier AS15 - plain upper and lower half shells with locating tags

Clearance in bearings

0.022 - 0.040 mm (0.0009 - 0.0016 in.)

Big-end bearing thicknesses:

⇒

Red

1.803 - 1.800 mm (0.0710 - 0.0709 in.)

⇒

Blue

1.800 - 1.797 mm (0.0709 - 0.0707 in.)

⇒

Green

1.797 - 1.794 mm (0.0707 - 0.0706 in.)

⇒

Yellow

1.794 - 1.791 mm (0.0706 - 0.0705 in.)

⇒

Black

1.791 - 1.788 mm (0.0705 - 0.0704 in.)

Big-end end-float

0.19 - 0.29 mm (0.007 - 0.011 in.)

Connecting rods

Type

Forged steel H-sections with horizontally split big-ends

Distance between centres

151.31 - 151.41 mm (5.957 - 5.961 in.)

Gudgeon pins

Type

Semi-floating offset towards thrust side

Fit in connecting rods

Interference

⇒

Diameter - Red coded

17.997 - 18.000 mm (0.7085 - 0.7087 in.)

⇒

Diameter - Green coded

17.994 - 17.997 mm (0.7084 - 0.7085 in.)

⇒

Length

52.3 - 52.6 mm (2.059 - 2.071 in.)

⇒

Clearance in piston

0.011 mm (0.0004 in.)

Pistons

Type

Aluminium alloy, tin plated, thermal expansion with offset gudgeon pin

Piston diameter (at right angle to gudgeon pin and 10
mm (0.4 in. from bottom of skirt):

⇒

Grade A

79.965 - 79.980 mm (3.1482 - 3.1488 in.)

⇒

Grade B

79.981 - 79.995 mm (3.1489 - 3.1494 in.)

Clearance in bore 20 mm (0.75 in.) from bottom of
cylinder bore

0.034 - 0.035 mm (0.0013 - 0.0014 in.)

Maximum ovality

0.3 mm (0.012 in.)

Piston rings

Type:

⇒

Top compression ring

Chrome plated steel

⇒

2nd compression ring

Chrome plated cast iron

⇒

Oil control ring

Stainless steel top and bottom rails with expander ring

New ring to groove clearance:

⇒

Top compression ring

0.05 - 0.08 mm (0.0020 - 0.0031 in.)

⇒

2nd compression ring

0.04 - 0.07 mm (0.0012 - 0.0024 in.)

⇒

Oil control ring

0.010 - 0.180 mm (0.0004 - 0.0071 in.)

Ring fitted gap 20 mm (0.75 in) from top of bore:

General

GENERAL DATA

04-12

⇒

Top compression ring

0.20 - 0.35 mm (0.008 - 0.014 in.)

⇒

2nd compression ring

0.28 - 0.45 mm (0.011 - 0.018 in.)

⇒

Oil control ring

0.25 - 1.00 mm (0.010 - 0.039 in.)

Piston ring width:

⇒

Top compression ring

3.1

0.15 mm (0.122

0.006 in.)

⇒

2nd compression ring

3.15 - 3.45 mm (0.124 - 0.136 in.)

⇒

Oil control ring

2.286 - 2.438 mm (0.090 - 0.096 in.)

Camshaft

Type

Twin camshafts on each cylinder bank retained by camshaft carrier,
line bored with cylinder head. Reluctor for camshaft sensor mounted
on left hand inlet camshaft

Camshaft identification:

⇒

Inlet

Orange paint mark

⇒

Exhaust

Blue paint mark

Bearings

5 per camshaft

Drive

Toothed belt driven from crankshaft to front of inlet camshafts, 2 x
short toothed belts from rear of inlet camshafts to exhaust camshafts

Camshaft end-float

0.06 - 0.19 mm (0.002 - 0.007 in.)

⇒

Service limit

0.3 mm (0.012 in.)

Bearing clearance

0.025 - 0.059 mm (0.0010 - 0.0023 in.)

⇒

Service limit

0.1 mm (0.004 in.)

Tappets

Type

Hydraulic self-adjusting, directly operated from camshafts

Tappet outside diameter

32.959 - 32.975 mm (1.2976 - 1.2982 in.)

Valve timing

Inlet valves:

⇒

Opens

⇒

Closes

BTDC

ABDC

Exhaust valves:

⇒

Opens

⇒

Closes

BBDC

ATDC

Valve maximum lift:

Inlet valves

8.2 mm (0.32 in.)

Exhaust valves

8.8 mm (0.35 in.)

Valves

Stem diameter:

⇒

Inlet valves

5.952 - 5.967 mm (0.2343 - 0.2349 in.)

⇒

Exhaust valves

5.947 - 5.962 mm (0.2341 - 0.2347 in.)

Stem to guide clearance:

Inlet valves

0.033 - 0.063 mm (0.0013 - 0.0025 in.)

⇒

Service limit

0.07 mm (0.0028 in.)

Exhaust valves

0.038 - 0.078 mm (0.0015 - 0.0013 in.)

⇒

Service limit

0.11 mm (0.0043 in.)

Valve stem fitted height:

⇒

New

38.93 - 39.84 mm (1.533 - 1.569 in.)

⇒

Service limit

40.10 mm (1.579 in.)

Valve guide fitted height

6.0 mm (0.24 in.)

Valve guide inside diameter

6.000 - 6.025 mm (0.2362 - 0.2372 in.)

General

Content .. 10 11 12 13 ..